High capacity anodes

ABSTRACT

A novel anode for a lithium battery cell is provided. The anode contains silicon nanoparticles embedded in a solid polymer electrolyte. The electrolyte can also act as a binder for the silicon nanoparticles. A plurality of voids is dispersed throughout the solid polymer electrolyte. The anode may also contain electronically conductive carbon particles. Upon charging of the cell, the silicon nanoparticles expand as take up lithium ions. The solid polymer electrolyte can deform reversibly in response to the expansion of the nanoparticles and transfer the volume expansion to the voids.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application 61/085,790, filed Aug. 1, 2008, which is incorporated by reference herein.

BACKGROUND OF THE INVENTION Field of the Invention

This invention relates generally to electrodes for batteries, and, more specifically, to high capacity nanostructured anodes for lithium batteries.

There has been much interest in lithium batteries as they have the highest specific energy (up to 180 Wh/kg) and energy density (up to 550 Wh/L) among chemical and electrochemical energy storage systems. Currently, lithium ion batteries are used for portable electronics, such as laptops and cell phones. There may also be use for lithium ion batteries in transportation systems, such as bicycles or automobiles.

Graphitic carbon has been the negative electrode material of choice for conventional Li-ion batteries. Graphitic carbon is distinguished by its stable cycle properties and its very high safety. In a conventional Li-ion cell, the anode is made from graphitic carbon, the cathode is a metal oxide, and the electrolyte is a lithium salt in an organic solvent. The typical cathode half reaction is:

The anode half reaction is:

The graphitic intercalation anode allows Li ions to intercalate and de-intercalate reversibly at relatively low potentials (0-0.3 V) with respect to Li/Li⁺. At such low potentials, the organic electrolyte is reductively unstable, but in the first few cycles it undergoes a surface reaction with the graphite and with impurities and/or electrolyte to form a so-called solid electrolyte interface (SEI) layer on the graphitic surface. The SEI layer is ionically conductive and allows transfer of ions between the electrolyte and the underlying graphite. The SEI also protects against further reduction of the electrolyte.

Graphitic carbon in a negative electrode undergoes a relatively small (compared to pure Li metal) volume change (<40%) during the insertion/extraction of lithium, i.e., the electrode remains stable over multiple cycles. However, graphitic carbon's very low potential (about 100-200 mV) relative to Li/Li⁺ is disadvantageous. A further drawback to graphitic carbon is its relatively low charge capacity (about 372 mAh/g or 818 Ah/L of graphite), which is only about one tenth the theoretical electrochemical charge capacity achievable with lithium metal (3862 mAh/g and 2047 Ah/L of lithium).

Lithium can form well-defined intermetallic/intercalation phases (Li_(x)M) with numerous metals M (M=A1, Si, Ge, Sn, Pb, Sb, Mg, etc.), their alloys (Si—Sn, Cu—Sn, Sb—Sn, etc.) and with metal oxides (SnO₂, etc.) at fairly low potentials with respect to Li/Li⁺ at room temperature. In general the reversible “lithiation” reaction can be written as:

The effort to make lithium-ion batteries with high specific energy, these materials have been investigated as promising negative electrode (anode) materials. In particular, silicon-based alloys with high theoretical specific capacity (e.g., nearly 4200 mAh g⁻¹ for Li₂₂Si₅) have been studied extensively as a replacement for graphite. Yet battery cells that use M-lithium alloys as active anode material have not been able to maintain their high capacity on prolonged cycling.

Upon lithium insertion and extraction, many of these metals and their alloys undergo significant changes in volume, ranging from more than 200% to even as much as 400% in some cases. Thus repeated charge/discharge cycles often result in cracking of active material and/or electrolyte binder and the resulting loss of electrical conduction paths.

In U.S. Patent Application Publication 2007/0202403, published Aug. 30, 2007, Oh et al. describe using a nanocomposite binder made of carbon nanotubes in a photo- or thermo-polymerizable material with silicon- or tin-based anode active material particles as an anode in a lithium battery. They state that such a binder enables stable maintenance of adhesion between the anode active material particles as they undergo significant volume changes during charge/discharge battery cycles, thereby preventing volume changes during cycling. Yet if it were possible to prevent expansion of the anode active material particles, it would not be possible for the lithium ions to insert themselves into the particles; it would not be possible to charge the battery. A liquid or solid electrolyte is used in the anode. If the anode active material particles do expand, no teaching is given as to how the extra volume would be accommodated.

In U.S. Patent Application Publication 2008/0044732, published Feb. 21, 2008, Salot et al. describe an anode for a lithium battery that has silicon nanowires extending from a current-collecting substrate. A solid electrolyte rests on the free ends of the nanowires creating closed cavities between the nanowires. Care is taken to be sure that the cavities are large enough to accommodate expansion of the nanowires during lithium insertion. Although this may solve some of the problems discussed above, this arrangement offers a very small contact area, only at the nanowires ends between the electrolyte and the anode active material, thus making sacrifices in battery rate performance.

Thus, there is a tremendous need for the development of an anode /electrolyte system for these promising metal, alloy, and oxide active anode materials so that lithium batteries can realize their full potential. If it were possible to use these high theoretical capacity materials reversibly without degradation in battery performance, substantial increases in the energy densities of lithium batteries would be possible.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing aspects and others will be readily appreciated by the skilled artisan from the following description of illustrative embodiments when read in conjunction with the accompanying drawings.

FIGS. 1 a-1 c are schematic cross-section illustrations of a particle of anode active material as it undergoes lithium insertion.

FIG. 2 is a schematic cross-section illustration of an active material nanoparticle embedded in an electrode as it undergoes lithiation.

FIG. 3 shows schematic cross section illustrations of alloy nanoparticles embedded in a solid polymer electrolyte before (A) and after (B) insertion of lithium.

FIG. 4 shows schematic cross section illustrations of novel electrodes whose active material is in the form of (A) nanoparticles and (B) linear nanostructures.

FIG. 5 is a schematic cross-section illustration of a battery cell with a novel negative electrode, according to an embodiment of the invention.

FIG. 6 is a schematic drawing of a diblock copolymer and a domain structure it can form.

FIG. 7 is a schematic drawing of a triblock copolymer and a domain structure it can form.

FIG. 8 is a schematic drawing of a triblock copolymer and a domain structure it can form.

DETAILED DESCRIPTION

The preferred embodiments are illustrated in the context of electrodes in a lithium battery. The skilled artisan will readily appreciate, however, that the materials and methods disclosed herein will have application in a number of other contexts where ion insertion into anode materials is desirable, particularly where accommodation of volume change is important.

In accordance with an aspect of the present invention, the need described above can be met with a novel anode that uses an ionically-conductive solid polymer material as both binder and electrolyte in combination with high-capacity anode active material particles. The solid polymer electrolyte material has material properties that allow it to stretch and a configuration that allows it to contract as the active material particles swell and shrink with insertion and extraction of lithium. The solid polymer electrolyte is able to transfer the increased volume to voids within the anode and to retain adhesion with the active material particles, even as they undergo significant volume changes during charge/discharge cycles of the battery.

In accordance with another aspect of the invention, a lithium secondary battery that employs the novel anode is provided.

These and other objects and advantages of the present invention will become more fully apparent from the following description taken in conjunction with the accompanying drawings.

In this disclosure, the terms “negative electrode” and “anode” are both used to mean “negative electrode”. Likewise, the terms “positive electrode” and “cathode” are both used to mean “positive electrode”.

The term “solid polymer” is used herein to mean solid and semi solid (gel) materials that can support and maintain a porous void structure. pores are compressible.

The term “nanostructure” is used herein to mean a structure that has at least two dimensions in the nanometer range. An exemplary nanostructure can be approximately equiaxed, such as a nanoparticle or nanosphere; or it can be linear, such as a nanorod, nanofiber, nanotube, or nanowire.

In some arrangements, approximately equiaxed nanostructures have a diameter between about 5 nm and 1 μm. In some arrangements, approximately equiaxed nanostructures have a diameter between about 5 nm and 500 nm. In some arrangements, approximately equiaxed nanostructures have a diameter between about 5 nm and 100 nm. In some arrangements, approximately equiaxed nanostructures have a diameter between about 5 nm and 50 nm.

In some arrangements, linear nanostructures have a diameter between about 1 nm and 1 μm. In some arrangements, linear nanostructures have a diameter between about 1 nm and 500 nm. In some arrangements, linear nanostructures have a diameter between about 1 nm and 100 nm.

The embodiments of the invention are described most often using the example of silicon as the nanostructured active anode material. It should be understood that the embodiments of the invention can also find utility when other metals, alloys, or metal oxides, which can form well-defined intermetallic/intercalation phases with lithium, are used instead of the silicon. Examples of appropriate nanostructure material include, but are not limited to, any one or more of metals such as, aluminum (Al), germanium (Ge), tin (Sn), lead (Pb), antimony (Sb), magnesium (Mg), copper, nickel or alloys or mixtures thereof; Si alloys with elements such as tin (Sn), nickel (Ni), copper (Cu), iron (Fe), cobalt (Co), manganese (Mn), zinc (Zn), indium (In), silver (Ag), titanium (Ti), germanium (Ge), bismuth (Bi), antimony (Sb), and chromium (Cr); silicon oxides and carbides; alloys such as Cu—Sn, Sb—Sn; and metal oxides such as SnO₂.

Lithium is stored in an anode host material in ionic, not atomic, form. Thus, the lithium packing densities within the alloys also reflect the theoretical charge capacities of the alloys. Table 1 shows the lithium volumetric packing density in unalloyed, metallic lithium, as well as in a few lithium alloys of interest:

TABLE 1 Lithium Packing Material Density (mol L⁺⁺¹) Metallic Li 76.36 Li₂₂Si₅ 88.56 Li₂₂Sn₅ 75.47 Li₂₂Pb₅ 72.17

The Li packing densities in the alloys shown in Table 1 are close to the Li packing density in lithium metal. In one case, Li₂₂Si₅, the Li packing density is even higher than it is in metallic lithium. The cycling efficiency of lithium metal is only about 99%, so that even after just 100 cycles, the amount of lithium available to the battery falls to 36%. Thus it is customary to provide as much as three to four times excess lithium to prolong cell life.

Some data suggest that lithium alloy electrodes may have higher lithium alloy cycling efficiencies than do lithium metal electrodes. In that case, there would be less need to add excess active material to the electrode. Thus, lithium alloy electrodes may be able to provide even more useful lithium in a smaller volume than indicated by the lithium packing densities shown in Table 1. Volumetric energy density is especially important in consumer electronics, where battery volume can be critical. Anode materials based on lithium alloys also have the advantage that lithium dendrite formation during cell charging does not occur as it does with metallic lithium anodes. Thus, these lithiated alloys are very interesting candidates for the next generation of lithium battery anodes.

The main problem with using lithiated alloys as active anode material in conventional anodes is the large volume expansion they experience with lithium insertion (i.e., during cell charging). The volume increase can be more than 200% and even as large as 400% in some cases. As a cell discharges, lithium is extracted from the active material, and the material shrinks. Thus, as the cell is cycled, the anode active material experiences repeated expansion and contraction. In conventional anodes, active material particles are held together with a rigid binder, such as PVDF (polyvinyl difluoride), to form an open network or matrix that can be filled with liquid electrolyte. It is important to fill the network with as much liquid electrolyte as possible in order to maximize the active material/electrolyte contact area. But, such a structure is incompressible and cannot accommodate any changes in active material volume. Thus, the active material particles and the binder holding them in place experience very large stresses during cycling. This has led to three undesirable outcomes: disintegration of the anode active material particles, exfoliation of the polymeric binder at the particle surfaces, and breaking up of the binder that holds the anode together.

In general, metallic and intermetallic anode host materials, other than layer materials such as graphite, break into fragments after a few cycles of lithium insertion and extraction due to the large volume changes that occur during these processes. The fragments can be isolated and may no longer be able to participate in the electrochemical reactions of the anode. In addition, as the particles expand, stress is transmitted from the particles to the binder matrix. Such stress can cause non-reversible plastic failure in the binder, leading to loss of overall anode film integrity.

As an anode is charged, lithium penetrates small active anode material particles within the anode. FIG. 1 a shows one such active material particle 100 before charging. The particle 100 has an outside surface 105. In an exemplary embodiment, the particle 100 is silicon. In FIG. 1 b, Li⁺ ions 110 are about to penetrate through the surface 105 to lithiate the particle 100. FIG. 1 c shows the particle 100 at some time after litiation has begun. Li⁺ ions have penetrated the surface 105 and diffused into the particle 100, inserting themselves into the silicon matrix to form a series of Si—Li mixtures or phases 130. The original unlithiated silicon particle 100 occupies a much smaller volume than any of the continuously-forming Si—Li mixtures or phases 130. In general, the volume increase is a function of the Li⁺ concentration. At full Li⁺ capacity, the volume increase can be as much as 400%.

FIG. 2A is a schematic cross-section illustration of a silicon nanoparticle 210 in a typical anode. At first, the active material nanoparticle 210 contains little or no lithium. The nanoparticle 210 is surrounded by a non-compressible environment 220, made up of some combination of binder, liquid electrolyte, and, optionally, conductive carbon particles such as carbon black. For ease of illustration, no distinction has been made among the various components of the non compressible environment 220. Of course, an anode contains very many nanoparticles dispersed within the binder and electrolyte. The entire battery, and, by extension, the anode, is enclosed ultimately by its packaging, which forms a rigid boundary for the entire battery volume. For the purpose of this illustration, the local environment 220 is shown to end at a rigid boundary indicated by line 250, to represent the environment experienced by the nanoparticle 210.

As shown in FIG. 2B, lithium insertion into the silicon nanoparticle 210 causes the nanoparticle to swell to a larger size as indicated by the dashed line 230. Gray arrows show the direction of expansion of the nanoparticle 210. The non-compressible and rigidly bound environment 220 cannot accommodate the increasing size of the silicon nanoparticle 210 and pushes back with an equal and opposite force, as indicated by the black arrows.

The stress caused by this process can cause the silicon nanoparticle 210 and/or binder in the environment 220 to crack. If the silicon nanoparticle 210 breaks apart, there is irreversible capacity loss; there is lithium tied up in the broken silicon, and that lithium can no longer cycle between the positive and negative electrodes. Furthermore, there is less total active material available to receive cycling lithium, as portions of the broken silicon are no longer actively connected to the ionic percolation network within the electrode. If there is no free volume for accommodating the expansion of the silicon nanoparticle, the surrounding binder/active material/carbon composite 220 may undergo non-reversible deformation as the stress increases beyond the yield stress of the composite, resulting in loss of mechanical integrity of the anode film.

There have been a number of studies done to determine the fracture properties of nanoparticles. When a particle is larger than its critical fracture length, a fracture can move through the particle. The critical fracture length is determined by material properties; it is directly proportional to the square of the fracture toughness, and inversely proportional to the square of the yield stress. For materials that undergo brittle failures (ceramics, glasses etc.), fracture occurs through nucleation of cracks and their subsequent propagation along dislocations. Dislocations, however, are statistical in nature; reducing the size of a particle also reduces the number of dislocations it can contain. Dislocations are extremely rare in nanocrystals, e.g., crystalline particles that are smaller than about 20 nm. By making active material particles very small, smaller than the critical fracture length, the probability of fracture can be reduced. This suggests that various useful nanostructured geometries, such as nanorods, nanowires, nanotubes, nanoparticles can be used to mitigate disintegration of anode active materials. The idea of using nano-sized intercalation hosts to prevent fracturing of the host materials has been demonstrated by several researchers. See for example, Gao, B., Sinha, S., Fleming, L. & Zhou, O., Adv. Mater. 13, 816-819 (2001) or Kasavajjula, U. et al. Journal of Power Sources 163, 1003-1039 (2007), which is included by reference herein.

Among nanostructured anode materials, linear structures have received considerable attention because they seem to provide improved stress distribution and percolation for electronic transport. Nevertheless, even when anode active material particles do not crack, there has not yet been a good way for an anode to accommodate the volume increase of the particles upon lithium insertion. The overall failure of anode films because of stress transfer between the particles and the binder material is a more difficult problem to solve. As has been discussed above, a rigid binder matrix filled with either a liquid or solid electrolyte is incompressible and prone to cracking as a result of the stress.

Another problem that limits the use of metallic and intermetallic anode host material particles is that during cycling, a stable solid electrolyte interface (SEI) protective layer is not known to form on the particle surfaces. Using nanoparticle-sized active material inherently exposes a large active surface area, which in turn means a large overall rate of electrolyte reduction at the surface in the absence of a protective layer on the anode particles. As discussed above for graphitic anodes, organic electrolytes undergo a surface reaction with the graphite particles during the first few charge/discharge cycles, thus forming an SEI layer on the graphitic surfaces. Although the SEI layer removes some amount of lithium from electrochemical cycling, it also protects against further reduction of the electrolyte and further loss of lithium. Even if a somewhat stable SEI layer can be formed on high capacity alloy particles during the first few cycles, as the particles expand and contract, the SEI layer would crack, exposing fresh surfaces that are available for continued electrolyte reduction reactions and removal of additional lithium from cycling. Hence, high capacity alloys exhibit continual, irreversible capacity loss, canceling out the advantages that are expected from materials with such high theoretical capacities.

FIG. 3A shows silicon nanoparticles 310 surrounded by a solid polymer electrolyte 320 which provides a conductive path for ions to reach the nanoparticles 310 in an anode, according to an embodiment of the invention. The solid electrolyte 320 also acts as a binder, holding the nanoparticles in well-dispersed positions. In one embodiment of the invention, no additional binder material is used, thereby significantly reducing or eliminating the f inactive material in the electrode. In another embodiment of the invention, additional binder material, such as PVDF (polyvinylidene fluoride) (not shown), is used to ensure that the nanoparticles 310 are fixed in a well-dispersed arrangement. The solid electrolyte 320 also contains voids, one of which 340 is shown in FIG. 3A. In some arrangements, the electrolyte 320 also contains conductive carbon particles such as carbon black (not shown) to provide electronic conductivity. In some arrangements, no carbon black is used because the electrode already has sufficient electronic conductivity. As discussed above for FIG. 2, a rigid boundary 350 is shown around the solid polymer electrolyte 320 for ease of illustration. At first, silicon nanoparticles 310 contain little or no lithium. As lithium penetrates into the silicon nanoparticles 310, the nanoparticles swell to larger sizes as indicated by the dashed lines 330. The solid electrolyte 320 has sufficient elasticity that it can deform reversibly in response to expansion of the nanoparticles 310. But, of course, the solid electrolyte 320 is incompressible. If there were no void 340 within the boundary 350, there would be no space to which the electrolyte 320 could move, and the electrolyte 320 would push back on the particles 310, causing stress and cracking in the particles 310 and/or the solid electrolyte 320, as has been discussed above in FIG. 2.

In the embodiment of the invention shown in FIGS. 3A and 3B, the void 340 in the electrolyte 320 is compressible. As the nanoparticles 310 incorporate Li ions and swell, the electrolyte 320 maintains contact with the nanoparticles 310 as it transfers the volume expansion to the void 340. As shown in FIG. 3B, fully-lithiated active material nanoparticles have swollen to their largest size 330, and the void 340 has shrunk to a smaller size 345 without breaching the rigid boundary 350. When the nanoparticles 310 release the Li ions, their volume decreases. The solid electrolyte 320, in turn, pulls away from the void 345, increasing the volume of the void 345. The solid electrolyte 320 has good adhesion to the nanoparticles 310 and thus maintains good contact with the surfaces of the nanoparticles 310 as the nanoparticles 310 contract. Thus the void 340/345 enables the anode to accommodate the changes in the volume of the nanoparticles 310/330 as lithium is inserted into and extracted from the nanoparticles 310/330.

FIG. 4A shows a portion of a novel electrode 405, according to an embodiment of the invention. The electrode 405 contains silicon nanoparticles 410 embedded in a solid polymer electrolyte 420. Voids 425 are dispersed throughout the electrolyte 420. The anode 405 may also contain other components that are not shown in FIG. 4A. In one arrangement, additional binder material, such as PVDF, is used to ensure that the nanoparticles 410 are fixed in a well-dispersed arrangement. In one arrangement, there are electronically conductive carbon particles dispersed in the electrolyte 420. In another arrangement, there is a current collector adjacent the electrode 405. Upon charging of a lithium cell with such an anode 405, the silicon nanoparticles 410 expand as they take up lithium ions. As discussed above, the surrounding electrolyte 420 can deform reversibly in response to the expansion of the nanoparticles and transfer the volume expansion to the voids 425. In some arrangements, more than one electrolyte can be used in the electrode 405.

FIG. 4B shows a portion of a novel electrode 407, according to an embodiment of the invention. The electrode 407 contains linear nanostructures 412, such as silicon nanowires, embedded in a polymer electrolyte 420. Although the linear nanostructures 412 are shown aligned, it should be understood that they can take on other ordered or disordered arrangements. Voids 425 are dispersed throughout the electrolyte 420. The anode 405 may also contain other components that are not shown in FIG. 4B. In one arrangement, additional binder material, such as PVDF, is used to ensure that the linear nanostructures 412 are fixed in a well-dispersed arrangement. In one arrangement, there are electronically conductive carbon particles dispersed in the electrolyte 420. In another arrangement, there is a current collector adjacent the electrode 407. Upon charging of a lithium cell with such an anode 407, the silicon nanowires 412 expand as take up lithium ions. As discussed above, the surrounding electrolyte 420 can deform reversibly in response to the expansion of the nanowires and transfer the volume expansion to the voids 425. In some arrangements, more than one electrolyte can be used in the electrode 407.

It should be noted that although conventional electrodes are often made as open networks of active material, binder, and conductive carbon particles such as carbon black, they are inactive and contain no electrolyte until the open space in the networks is filled with liquid electrolyte. Only after the liquid electrolyte is added is it possible for the electrodes to receive and release lithium ions and thus function as an electrochemical device. Such electrodes are not designed to retain voids after the electrolyte is added. Rather, care is taken to ensure that there are no voids after the electrolyte is added, as any void space would create a region where there is no electrolyte in contact with active material, thereby reducing the capacity of the device, a highly undesirable outcome. Also, voids or “free volume” cannot be maintained when a liquid electrolyte is used, as liquids cannot retain a porous structure.

Anode layers made from active material particles, solid electrolyte, and optional (carbon) electronically conductive particles can be made in a few different ways to create anode layers with voids according to embodiments of the invention. One such method is solvent casting and another is extrusion.

In solvent casting, active material particles, solid polymer electrolyte, and optional (carbon) electronically conductive particles are mixed together with a solvent that dissolves the polymer to form a slurry. The slurry contains a suspension of active material particles in the polymer solution. The slurry is deposited (e.g., poured) onto a substrate and allowed to dry. As the mixture dries, solvent leaves, and voids form in the polymer electrolyte. The size and distribution of the voids depend on a few factors such as the mechanical properties of the polymer and the dilution of the polymer. The more dilute the polymer (i.e., the higher the ratio of solvent to polymer), the higher the proportion of void space that can be created. The more tough the polymer, the better the polymer can retain the void structure without collapsing in on itself. Another factor that can influence the void structure in the polymer electrolyte is the size and size distribution of the active material (and optional conductive) particles. In some arrangements, foaming agents or surfactants can be added to the slurry to facilitate void formation.

In extrusion, a mixture of active material particles, polymer electrolyte, and optional (carbon) electronically conductive particles are fed into an extruder. The temperature of the extrusion is chosen above the melting temperature/glass transition temperature of the mixture. As the mixture is fed into the extruder, and the polymer melts in the extruder, an inert gas, such as argon, is added to make voids in the extruded anode. Again, the more tough the polymer, the better the polymer can retain the void structure without collapsing in on itself. In some arrangements, foaming agents or surfactants can be added to the slurry to facilitate void formation. This method is also known as foam extrusion.

FIG. 5 is a schematic cross-section illustration of a battery cell 500 with a novel negative electrode 505, according to an embodiment of the invention. The negative electrode 505 is as has been described above in any of the embodiments of the invention. The cell 500 also has a positive electrode 560. There is an electrolyte layer 570 between the negative electrode 505 and the positive electrode 560. In some arrangements, there can be a current collector 580 adjacent the positive electrode 560 and/or a current collector 590 adjacent the negative electrode 505.

There are a variety of materials that are suitable for use as solid polymer electrolyte binders in the novel electrode as described above. In general, any polymer electrolyte that is solid or semi-solid at cell operating temperatures, has good ionic conductivity, has sufficient elasticity that it can deform reversibly and can adhere to anode active material particles can be used.

The electrochemical stability of the electrolyte in the anode in relation to the active anode material is very important as reactions can remove both active anode material and lithium from active participation in the electrochemistry of the cell and thus result in capacity fade for the cell. In general, solid polymer electrolytes are reductively more stable compared to liquid electrolytes.

In one embodiment of the invention, the solid polymer electrolyte used in the anode or in any other part of the cell can be a polyethylene oxide, a polysulfone, a polyacrylonitrile, a siloxane, a polyether, a polyamine, a linear copolymers containing ethers or amines, an ethylene carbonate, a polysiloxane grafted with small molecules or oligomers that include polyethers and/or alkylcarbonates or any other polymers or combination of polymers that have a high enough ionic conductivity, when mixed with an appropriate salt, to act as an electrolyte in a cell, such as a lithium ion cell. Salts listed below as appropriate for block copolymer electrolyte can also be used with any of these electrolytes. Another example of a suitable solid polymer electrolyte is Nafion®. Polymers that are liquid at battery cell operating temperatures can be made solid through cross-linking, as is well known in the art.

In another embodiment of the invention, the solid polymer electrolyte can be replaced by a ceramic-based electrolyte, such as lithium phosphorous oxynitride or nascion.

In yet another embodiment of the invention, the solid polymer electrolyte in the novel electrode is a block copolymer electrolyte.

Nanostructured Block Copolymer Electrolytes

As described in detail above, a block copolymer electrolyte can be used in the embodiments of the invention.

FIG. 6A is a simplified illustration of an exemplary diblock polymer molecule 600 that has a first polymer block 610 and a second polymer block 620 covalently bonded together. In one arrangement both the first polymer block 610 and the second polymer block 620 are linear polymer blocks. In another arrangement, either one or both polymer blocks 610, 620 has a comb (or branched) structure. In one arrangement, neither polymer block is cross-linked. In another arrangement, one polymer block is cross-linked. In yet another arrangement, both polymer blocks are cross-linked.

Multiple diblock polymer molecules 600 can arrange themselves to form a first domain 615 of a first phase made of the first polymer blocks 610 and a second domain 625 of a second phase made of the second polymer blocks 620, as shown in FIG. 6B. Diblock polymer molecules 600 can arrange themselves to form multiple repeat domains, thereby forming a continuous nanostructured block copolymer material 640, as shown in FIG. 6C. The sizes or widths of the domains can be adjusted by adjusting the molecular weights of each of the polymer blocks.

In one arrangement the first polymer domain 615 is ionically conductive, and the second polymer domain 625 provides mechanical strength to the nanostructured block copolymer.

FIG. 7A is a simplified illustration of an exemplary triblock polymer molecule 700 that has a first polymer block 710 a, a second polymer block 720, and a third polymer block 710 b that is the same as the first polymer block 710 a, all covalently bonded together. In one arrangement the first polymer block 710 a, the second polymer block 720, and the third copolymer block 710 b are linear polymer blocks. In another arrangement, either some or all polymer blocks 710 a, 720, 710 b have a comb (or branched) structure. In one arrangement, no polymer block is cross-linked. In another arrangement, one polymer block is cross-linked. In yet another arrangement, two polymer blocks are cross-linked. In yet another arrangement, all polymer blocks are cross-linked.

Multiple triblock polymer molecules 700 can arrange themselves to form a first domain 715 of a first phase made of the first polymer blocks 710 a, a second domain 725 of a second phase made of the second polymer blocks 720, and a third domain 715 b of a first phase made of the third polymer blocks 710 b as shown in FIG. 7B. Triblock polymer molecules 700 can arrange themselves to form multiple repeat domains 425, 415 (containing both 415 a and 415 b), thereby forming a continuous nanostructured block copolymer 730, as shown in FIG. 7C. The sizes of the domains can be adjusted by adjusting the molecular weights of each of the polymer blocks.

In one arrangement the first and third polymer domains 715 a, 715 b are ionically conductive, and the second polymer domain 725 provides mechanical strength to the nanostructured block copolymer. In another arrangement, the second polymer domain 725 is ionically conductive, and the first and third polymer domains 715 provide a structural framework.

FIG. 8A is a simplified illustration of another exemplary triblock polymer molecule 800 that has a first polymer block 810, a second polymer block 820, and a third polymer block 830, different from either of the other two polymer blocks, all covalently bonded together. In one arrangement the first polymer block 810, the second polymer block 820, and the third copolymer block 830 are linear polymer blocks. In another arrangement, either some or all polymer blocks 810, 820, 830 have a comb (or branched) structure. In one arrangement, no polymer block is cross-linked. In another arrangement, one polymer block is cross-linked. In yet another arrangement, two polymer blocks are cross-linked. In yet another arrangement, all polymer blocks are cross-linked.

Multiple triblock polymer molecules 800 can arrange themselves to form a first domain 815 of a first phase made of the first polymer blocks 810 a, a second domain 825 of a second phase made of the second polymer blocks 820, and a third domain 835 of a third phase made of the third polymer blocks 830 as shown in FIG. 8B. Triblock polymer molecules 800 can arrange themselves to form multiple repeat domains, thereby forming a continuous nanostructured block copolymer 840, as shown in FIG. 8C. The sizes of the domains can be adjusted by adjusting the molecular weights of each of the polymer blocks.

In one arrangement the first polymer domains 815 are ionically conductive, and the second polymer domains 825 provide mechanical strength to the nanostructured block copolymer. The third polymer domains 835 provides an additional functionality that may improve mechanical strength, ionic conductivity, chemical or electrochemical stability, may make the material easier to process, or may provide some other desirable property to the block copolymer. In other arrangements, the individual domains can exchange roles.

Choosing appropriate polymers for the block copolymers described above is important in order to achieve desired electrolyte properties. In one embodiment, the conductive polymer (1) exhibits ionic conductivity of at least 10⁻⁵ Scm⁻¹ at electrochemical cell operating temperatures when combined with an appropriate salt(s), such as lithium salt(s); (2) is chemically stable against such salt(s); and (3) is thermally stable at electrochemical cell operating temperatures. In one embodiment, the structural material has a modulus in excess of 1×10⁵ Pa at electrochemical cell operating temperatures. In one embodiment, the third polymer (1) is rubbery; and (2) has a glass transition temperature lower than operating and processing temperatures. It is useful if all materials are mutually immiscible.

In one embodiment of the invention, the conductive phase can be made of a linear or branched polymer. Conductive linear or branched polymers that can be used in the conductive phase include, but are not limited to, polyethers, polyamines, polyimides, polyamides, alkyl carbonates, polynitriles, and combinations thereof. The conductive linear or branched polymers can also be used in combination with polysiloxanes, polyphosphazines, polyolefins, and/or polydienes to form the conductive phase.

In another exemplary embodiment, the conductive phase is made of comb (or branched) polymers that have a backbone and pendant groups. Backbones that can be used in these polymers include, but are not limited to, polysiloxanes, polyphosphazines, polyethers, polydienes, polyolefins, polyacrylates, polymethacrylates, and combinations thereof. Pendants that can be used include, but are not limited to, oligoethers, substituted oligoethers, nitrile groups, sulfones, thiols, polyethers, polyamines, polyimides, polyamides, alkyl carbonates, polynitriles, other polar groups, and combinations thereof.

Further details about polymers that can be used in the conductive phase can be found in U.S. Provisional Patent Application No. 61/056,688, filed May 28, 2008, U.S. Provisional Patent Application No. 61/091,626, filed Aug. 25, 2008, U.S. Provisional Patent Application No. 61/145,518 filed Jan. 16, 2009, U.S. Provisional Patent Application No. 61/145,507, filed Jan. 16, 2009, U.S. Provisional Patent Application No. 61/158,257 filed Mar. 6, 2009, and U.S. Provisional Patent Application No. 61/158,241, filed Mar. 6, 2009, all of which are included by reference herein.

Further details about polymers that can be used in the conductive phase can be found in International Application Number PCT/US09/45356, filed May 27, 2009, U.S. Provisional Patent Application No. 61/091,626, filed Aug. 25, 2008, U.S. Provisional Patent Application No. 61/145,518, filed Jan. 16, 2009, U.S. Provisional Patent Application No. 61/145,507, filed Jan. 16, 2009, U.S. Provisional Patent Application No. 61/158,257, filed Mar. 6, 2009, and U.S. Provisional Patent Application No. 61/158,241, filed Mar. 6, 2009, all of which are included by reference herein.

There are no particular restrictions on the electrolyte salt that can be used in the block copolymer electrolytes. Any electrolyte salt that includes the ion identified as the most desirable charge carrier for the application can be used. It is especially useful to use electrolyte salts that have a large dissociation constant within the polymer electrolyte.

Suitable examples include alkali metal salts, such as Li salts. Examples of useful Li salts include, but are not limited to, LiPF₆, LiN(CF₃SO₂)₂, Li(CF₃SO₂)₃C, LiN(SO₂CF₂CF₃)₂, LiB(C₂O₄)₂, B₁₂F_(x)H_(12-x), B₁₂F₁₂, and mixtures thereof.

In one embodiment of the invention, single ion conductors can be used with electrolyte salts or instead of electrolyte salts. Examples of single ion conductors include, but are not limited to sulfonamide salts, boron based salts, and sulfates groups.

In one embodiment of the invention, the structural phase can be made of polymers such as polystyrene, polymethacrylate, poly(methyl methacrylate), polyvinylpyridine, polyvinylcyclohexane, polyimide, polyamide, polypropylene, polyolefins, poly(t-butyl vinyl ether), poly(cyclohexyl methacrylate), poly(cyclohexyl vinyl ether), poly(t-butyl vinyl ether), polyethylene, fluorocarbons, such as polyvinylidene fluoride, or copolymers that contain styrene, methacrylate, or vinylpyridine.

Additional species can be added to nanostructured block copolymer electrolytes to enhance the ionic conductivity, to enhance the mechanical properties, or to enhance any other properties that may be desirable.

The ionic conductivity of nanostructured block copolymer electrolyte materials can be improved by including one or more additives in the ionically conductive phase. An additive can improve ionic conductivity by lowering the degree of crystallinity, lowering the melting temperature, lowering the glass transition temperature, increasing chain mobility, or any combination of these. A high dielectric additive can aid dissociation of the salt, increasing the number of Li+ ions available for ion transport, and reducing the bulky Li+[salt] complexes. Additives that weaken the interaction between Li+ and PEO chains/anions, thereby making it easier for Li+ ions to diffuse, may be included in the conductive phase. The additives that enhance ionic conductivity can be broadly classified in the following categories: low molecular weight conductive polymers, ceramic particles, room temp ionic liquids (RTILs), high dielectric organic plasticizers, and Lewis acids.

Other additives can be used in the polymer electrolytes described herein. For example, additives that help with overcharge protection, provide stable SEI (solid electrolyte interface) layers, and/or improve electrochemical stability can be used. Such additives are well known to people with ordinary skill in the art. Additives that make the polymers easier to process, such as plasticizers, can also be used.

Further details about block copolymer electrolytes are described in U.S. patent application Ser. No. 12/225,934, filed Oct. 1, 2008, U.S. patent application Ser. No. 12/271,1828, filed Nov. 14, 2008, and PCT Patent Application Number PCT/US09/31356, filed Jan. 16, 2009, all of which are included by reference herein.

This invention has been described herein in considerable detail to provide those skilled in the art with information relevant to apply the novel principles and to construct and use such specialized components as are required. However, it is to be understood that the invention can be carried out by different equipment, materials and devices, and that various modifications, both as to the equipment and operating procedures, can be accomplished without departing from the scope of the invention itself. 

1. An electrode for an electrochemical lithium cell comprising: a solid polymer electrolyte, the electrolyte comprising a plurality of voids; and nanostructures comprising electrode active material, the nanostructures distributed throughout the solid polymer electrolyte;
 2. The electrode of claim 1, further comprising a binder to bind the nanostructures within the electrode.
 3. The electrode of claim 2 wherein the binder comprises PVDF. (or 3M cellulose)
 4. The electrode of claim 1 wherein the electrode contains no additional electrolytes.
 5. The electrode of claim 1 wherein the solid polymer electrolyte has a yield strain of 50-500% and an elastic modulus of 104-109 Pa.
 6. The electrode of claim 1 wherein the nanostructures are selected from the group consisting of nanorods, nanowires, nanotubes, and nanoparticles.
 7. The electrode of claim 1 wherein the nanostructures comprise carbon, aluminum, silicon, germanium, tin, lead, antimony, magnesium, copper, nickel or alloys or mixtures thereof.
 8. The electrode of claim 1 wherein the nanostructures comprise silicon.
 9. The electrode of claim 1 wherein the nanostructures comprise silicon alloys of tin (Sn), nickel (Ni), copper (Cu), iron (Fe), cobalt (Co), manganese (Mn), zinc (Zn), indium (In), silver (Ag), titanium (Ti), germanium (Ge), bismuth (Bi), antimony (Sb), and chromium (Cr) or mixtures thereof.
 10. The electrode of claim 1 wherein the nanostructures comprise silicon oxides or silicon carbides.
 11. The electrode of claim 1 wherein the nanostructures comprise a metal oxide.
 12. The electrode of claim 1 wherein the nanostructures have no dimension larger than their critical fracture length.
 13. The electrode of claim 1 wherein the nanostructures have no more than one dimension larger than their critical fracture length.
 14. The electrode of claim 1 wherein the nanostructures are approximately equiaxed and have a diameter between about 5 nm and 1 μm.
 15. The electrode of claim 1 wherein the nanostructures are approximately equiaxed and have a diameter between about 5 nm and 500 nm.
 16. The electrode of claim 1 wherein the nanostructures are approximately equiaxed and have a diameter between about 5 nm and 100 nm.
 17. The electrode of claim 1 wherein the nanostructures are approximately equiaxed and have a diameter between about 5 nm and 50 nm.
 18. The electrode of claim 1 wherein the nanostructures are linear and have a diameter between about 1 nm and 1 μm.
 19. The electrode of claim 1 wherein the nanostructures are linear and have a diameter between about 1 nm and 500 nm.
 20. The electrode of claim 1 wherein the nanostructures are linear and have a diameter between about 1 nm and 100 nm.
 21. The electrode of claim 1 wherein the plurality of voids has a total volume no smaller than four times the total volume of the nanostructures before lithiation.
 22. The electrode of claim 1 wherein the plurality of voids has a total volume no smaller than three times the total volume of the nanostructures before lithiation.
 23. The electrode of claim 1 wherein the plurality of voids has a total volume no smaller than two and a half times the total volume of the nanostructures before lithiation.
 24. The electrode of claim 1 wherein the plurality of voids has a total volume no smaller than twice the total volume of the nanostructures before lithiation.
 25. The electrode of claim 1 wherein the voids have a volume that is between about 10% and 60% of the electrode.
 26. The electrode of claim 1, further comprising between about 0 and 10 weight percent conductive carbon particles.
 27. The electrode of claim 1 wherein the solid polymer electrolyte comprises one or more polymers selected from the group consisting of the following optionally cross-linked polymers: polyethylene oxide, polysulfone, polyacrylonitrile, siloxane, polyether, polyamine, linear copolymers containing ethers or amines, ethylene carbonate, Nafion®, and polysiloxane grafted with small molecules or oligomers that include polyethers and/or alkylcarbonates.
 28. The electrode of claim 1 wherein the solid polymer electrolyte comprises a block copolymer.
 29. The electrode of claim 28 wherein the solid polymer electrolyte further comprises at least one lithium salt.
 30. The electrode of claim 28 wherein the block copolymer is either a diblock copolymer or a triblock copolymer.
 31. The electrode of claim 30 wherein a first block of the block copolymer is ionically conductive and is selected from the group consisting of polyethers, polyamines, polyimides, polyamides, alkyl carbonates, polynitriles, polysiloxanes, polyphosphazines, polyolefins, polydienes, and combinations thereof.
 32. The electrode of claim 30 wherein a first block of the block copolymer comprises an ionically-conductive comb polymer, which comb polymer comprises a backbone and pendant groups.
 33. The electrode of claim 32 wherein the backbone comprises one or more selected from the group consisting of polysiloxanes, polyphosphazines, polyethers, polydienes, polyolefins, polyacrylates, polymethacrylates, and combinations thereof.
 34. The electrode of claim 32 wherein the pendants comprise one or more selected from the group consisting of oligoethers, substituted oligoethers, nitrile groups, sulfones, thiols, polyethers, polyamines, polyimides, polyamides, alkyl carbonates, polynitriles, other polar groups, and combinations thereof.
 35. The electrode of claim 30 wherein a second block of the block copolymer is selected from the group consisting of polystyrene, polymethacrylate, poly(methyl methacrylate), polyvinylpyridine, polyvinylcyclohexane, polyimide, polyamide, polypropylene, polyolefins, poly(t-butyl vinyl ether), poly(cyclohexyl methacrylate), poly(cyclohexyl vinyl ether), poly(t-butyl vinyl ether), polyethylene, fluorocarbons, polyvinylidene fluoride, and copolymers that contain styrene, methacrylate, and/or vinylpyridine.
 36. An electrode for an electrochemical lithium cell comprising: a block copolymer electrolyte, the electrolyte comprising a plurality of voids; and silicon nanoparticles, the nanoparticles bound in the electrode by the block copolymer electrolyte.
 37. The electrode of claim 36, further comprising a binder to bind the nanostructures within the electrode.
 38. The electrode of claim 36 wherein the electrode contains no additional electrolytes.
 39. A lithium battery cell, comprising: a negative electrode according to the electrode of claim 1; a positive electrode; a solid polymer electrolyte layer between the negative electrode and the positive electrode, the electrolyte layer in ionic communication with both the negative electrode and the positive electrode.
 40. A method of making an anode for a lithium cell, comprising the steps of: combining active anode material particles, polymer electrolyte, optional foaming agent, and optional electronically conductive carbon particles together to make a mixture; forming the mixture into a anode with a porosity between about 10% and 60%.
 41. The method of claim 40 wherein the mixture comprises between about 60 and 96 wt % solvent.
 42. The method of claim 40 wherein the forming step comprises the steps of: adding a polymer solvent to the mixture; casting a film of the mixture; allowing the film to release the polymer solvent.
 43. The method of claim 40 wherein the forming step comprises the steps of: introducing the mixture to an extruder; adding an inert gas to the mixture; extruding the mixture to form a film. 